阅读说明：本技术 经由增材制造来定制风力涡轮台板的方法 (Method of customizing a wind turbine bedplate via additive manufacturing ) 是由 P·J·罗克 T·A·蒙特 A·詹尼兹 M·贝卢奇 于 2019-09-13 设计创作，主要内容包括：一种用于为具有不同负载需求的多个风力涡轮(10)定制台板(48)的方法包括为台板(48)形成多个基本体(56),其包括台板(48)中一个的近净形状。此外,方法包括确定风力涡轮(10)中每个的台板(48)的负载需求。此外,方法包括经由增材制造工艺将增材施加到多个基本体(56)的外表面(60),以便定制台板(48)中每个的结构能力,使得台板(48)中每个的结构能力可承受关于风力涡轮(10)中每个的负载需求。相应地,多个基本体(56)中每个的结构能力可相同或可不同。(A method for customizing a bedplate (48) for a plurality of wind turbines (10) having different load requirements includes forming a plurality of base bodies (56) for the bedplate (48) including a near-net shape of one of the bedplate (48). Further, the method includes determining a load demand of the bedplate (48) of each of the wind turbines (10). Further, the method includes applying additive to the outer surfaces (60) of the plurality of base bodies (56) via an additive manufacturing process in order to customize the structural capability of each of the platens (48) such that the structural capability of each of the platens (48) can withstand load demands with respect to each of the wind turbines (10). Accordingly, the structural capabilities of each of the plurality of base bodies (56) may be the same or may be different.)

1. A method for customizing a bedplate (48) for a plurality of wind turbines (10) having different load requirements, the method comprising:

forming a plurality of base bodies (56) for the platens (48), each of the base bodies (56) comprising a near net shape of one of the platens (48);

determining a load demand of a bedplate (48) of each of the wind turbines (10); and

applying an additive (58) to the outer surfaces (60) of the plurality of base bodies (56) via an additive manufacturing process in order to customize the structural capability of each of the platens (48) such that the structural capability of each of the platens (48) can withstand load requirements with respect to each of the wind turbines (10).

2. The method of claim 1, further comprising forming the plurality of base bodies (56) for the platen (48) via at least one of a casting process or welding.

3. The method of claim 2, wherein the casting process further comprises:

pouring a liquid material into a mould of a base body (56) of said platen (48); and

allowing the liquid material to solidify in the mould so as to form a plurality of elementary bodies (56) of the platen (48).

4. The method of any of the preceding claims, further comprising forming the plurality of base bodies (56) from at least one of steel, cast steel, iron, or ductile iron for the platen (48).

5. The method of any of the preceding claims, wherein determining the load demand of the bedplate (48) of each of the wind turbines (10) further comprises:

receiving, via a topology optimization module programmed in a controller, one or more boundary conditions for the platen (48);

determining, via the topology optimization module, an optimized load path for each of the platens (48) based on one or more boundary conditions with respect to the platens (48).

6. The method of claim 5, wherein applying the additive (58) to the outer surfaces (60) of the plurality of base bodies (56) via the additive manufacturing process further comprises printing one or more structural components at one or more locations on the outer surface (60) of each of the plurality of base bodies (56) to correspond to the optimized load path.

7. The method according to any one of the preceding claims, further comprising applying the additive (58) to outer surfaces (60) of the plurality of base bodies (56) as needed.

8. The method of any one of the preceding claims, wherein the additive manufacturing process comprises at least one of directed energy deposition, adhesive jetting, or material jetting.

9. The method of any of the preceding claims, wherein the additive (58) comprises at least one of a steel alloy or an iron alloy.

10. The method according to any one of the preceding claims, wherein the structural capacity of each of the plurality of basic bodies (56) is different.

11. A wind turbine (10) comprising:

a tower (12);

a nacelle (16), said nacelle (16) mounted atop said tower (12);

a rotor (18), the rotor (18) being fixed to the nacelle (16), the rotor (18) comprising a rotatable hub (20) and a plurality of rotor blades (22) mounted to the hub (20); and

a platen (48), the platen (48) positioned within the nacelle (16) and secured to the nacelle (16), the platen (48) comprising a base body (56) formed via at least one of casting or welding and one or more additive (58) regions applied to an outer surface (60) of the base body (56) via an additive manufacturing process such that a structural capacity of the platen (48) is designed to withstand a load requirement of the platen (48).

Technical Field

The present disclosure relates generally to wind turbines, and more particularly to methods for customizing wind turbine platens via additive manufacturing.

Background

Generally, a wind turbine includes a tower, a nacelle mounted on the tower, and a rotor coupled to the nacelle. The rotor generally includes a rotatable hub and a plurality of rotor blades coupled to and extending outwardly from the hub. Each rotor blade may be spaced about the hub to facilitate rotating the rotor to enable conversion of the kinetic energy into usable mechanical energy, which may then be transmitted to a generator disposed within the nacelle for generation of electrical energy. Typically, a gearbox is used to drive the generator in response to rotation of the rotor. For example, the gearbox may be configured to convert a low-speed, high-torque input provided by the rotor into a high-speed, low-torque output that may drive the generator. In addition, the wind turbine includes a bedplate that supports various components within the nacelle. The bedplate is the main structural component of the nacelle, which reacts loads from the rotor blades, through the tower and to the ground.

More particularly, FIG. 1 illustrates a perspective view of one embodiment of a wind turbine bedplate 1 according to conventional construction. As shown, the bedplate 1 supports at a minimum the main shaft 2 and gearbox (not shown) of the wind turbine. Thus, the bedplate 1 is designed to transfer thrust, torque and bending moments from the main shaft 2 and the gearbox to the tower. In addition, the bedplate 1 is designed to use appropriate materials and features for supporting the internal wind turbine equipment and/or various bolted connections (such as torque arms, yaw drives, etc.).

Typical wind turbine decks are formed via sand casting using ductile cast iron. Thus, the overall shape and design of conventional platens is limited by the manufacturing capabilities of the casting process. In addition, because a given wind turbine model may operate in different environments, wind turbine decks are generally designed to handle a variety of wind load conditions. Thus, many platens are over-designed or under-designed depending on the wind conditions of a particular wind turbine site.

Accordingly, an improved bedplate for a wind turbine and method of manufacturing the same that addresses the foregoing problems would be welcomed in the art.

Disclosure of Invention

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In one aspect, the present disclosure is directed to a method for customizing a bedplate for a plurality of wind turbines having different load requirements. The method includes forming a plurality of base bodies for the platens including a near net shape of one of the platens. Further, the method includes determining a load demand of the bedplate of each of the wind turbines. Further, the method includes applying additive to the outer surfaces of the plurality of base bodies via an additive manufacturing process in order to customize the structural capability of each of the platens such that the structural capability of each of the platens can withstand load demands with respect to each of the wind turbines. Accordingly, the structural capabilities of each of the plurality of basic bodies may be the same or may be different.

In one embodiment, the method may include forming a plurality of base bodies for the platen via at least one of a casting process or welding. For example, in certain embodiments, the casting process may include pouring the liquid material into a mold of the base body of the platen and allowing the liquid material to solidify in the mold so as to form the plurality of base bodies of the platen. In another embodiment, the method may include forming a plurality of base bodies for the platen from at least one of steel, cast steel, iron, or ductile iron.

In further embodiments, the step of determining the load demand of the platens of each of the wind turbines may include receiving, via a topology optimization module programmed in the controller, one or more boundary conditions for the platens, and determining, via the topology optimization module, an optimized load path for each of the platens based on the one or more boundary conditions for the platen.

In additional embodiments, the step of applying additive to the outer surface of the plurality of base bodies via the additive manufacturing process may comprise printing one or more structural components at one or more locations on the outer surface of each of the plurality of base bodies to correspond to the optimized load path. Thus, the method may include applying the additive to the outer surfaces of the plurality of base bodies as desired.

In certain embodiments, the additive manufacturing processes described herein may include, for example, directed energy deposition, binder jetting, material jetting, or any other suitable additive manufacturing technique. Thus, the additive used in the additive manufacturing process may comprise a steel alloy, an iron alloy, or a combination thereof, or the like.

In another aspect, the present disclosure is directed to a method for manufacturing a bedplate of a wind turbine. The method includes forming a base body of a bedplate of the wind turbine that includes a near-net shape of the bedplate. The method also includes determining a load demand of a bedplate of the wind turbine. Thus, the method includes applying additive to an outer surface of the base body of the deck via an additive manufacturing process in order to customize the structural capabilities of the deck so that the structural capabilities of the deck can withstand the load requirements of the deck. It is also to be understood that the method may further comprise any of the additional features and/or steps described herein.

In yet another aspect, the present disclosure is directed to a wind turbine. The wind turbine includes: a tower; a nacelle mounted atop a tower; a rotor secured to the nacelle, the rotor having a rotatable hub and a plurality of rotor blades mounted to the hub; and a deck positioned within and secured to the nacelle. Further, the platen includes: a base body formed via at least one of casting or welding; and one or more additive regions applied to an outer surface of the base body via an additive manufacturing process such that the structural capacity of the deck is designed to withstand the load requirements of the deck. It should also be understood that the wind turbine may also include any of the additional features described herein.

These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention.

Drawings

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 illustrates a perspective view of a bedplate of a wind turbine according to conventional construction;

FIG. 2 illustrates a perspective view of an embodiment of a wind turbine according to the present disclosure;

FIG. 3 illustrates a detailed interior view of an embodiment of a nacelle of a wind turbine according to the present disclosure;

FIG. 4 illustrates a perspective view of an embodiment of a bedplate of a wind turbine according to the present disclosure;

FIG. 5 illustrates a flow diagram of an embodiment of a method for manufacturing a bedplate of a wind turbine according to the present disclosure;

FIG. 6 illustrates a schematic view of an embodiment of a controller for determining an optimized load path for a bedplate of a wind turbine according to the present disclosure; and

FIG. 7 illustrates a flow diagram of one embodiment of a method for customizing a bedplate for a plurality of wind turbines having different load requirements according to the present disclosure.

Detailed Description

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, can be used with another embodiment to yield a still further embodiment. It is therefore intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

In general, the present disclosure relates to a method for manufacturing a bedplate of a wind turbine. The method includes forming a lightweight cast bedplate capable of meeting load requirements for most wind turbine sites, thereby reducing costs and using less material. For wind turbine sites where additional structure is required due to higher loads, additive manufacturing processes may be used, such as adding ribs and/or other structural components to the cast component, thereby enabling the bedplate to withstand higher loads.

Accordingly, the present disclosure provides many advantages not present in the prior art. For example, the bedplate of the present disclosure may be customized for a particular wind turbine site, thereby avoiding the problem of over-designing the bedplate in most applications. By enabling customization as needed with an additive manufacturing process, the bedplate of the present disclosure can be specifically designed to accommodate higher wind load environments only when needed.

Referring now to the drawings, FIG. 2 illustrates a perspective view of an embodiment of a wind turbine 10 according to the present disclosure. As shown, wind turbine 10 generally includes a tower 12 extending from a support surface 14, a nacelle 16 mounted on tower 12, and a rotor 18 coupled to nacelle 16. Rotor 18 includes a rotatable hub 20 and at least one rotor blade 22 coupled to hub 20 and extending outwardly from hub 22. For example, in the illustrated embodiment, the rotor 18 includes three rotor blades 22. However, in alternative embodiments, rotor 18 may include more or less than three rotor blades 22. Each rotor blade 22 may be spaced about hub 20 to facilitate rotating rotor 18 to enable kinetic energy to be converted from wind into usable mechanical energy, and subsequently, electrical energy. For example, hub 20 may be rotatably coupled to a generator 24 (FIG. 3) positioned within nacelle 16 to allow electrical energy to be generated.

Wind turbine 10 may also include a wind turbine controller 26 centralized within nacelle 16. However, in other embodiments, the controller 26 may be located at a location within any other component of the wind turbine 10 or outside of the wind turbine. Moreover, controller 26 may be communicatively coupled to any number of components of wind turbine 10 in order to control the components. Thus, the controller 26 may comprise a computer or other suitable processing unit. Thus, in several embodiments, the controller 26 may include suitable computer readable instructions that, when executed, configure the controller 26 to perform various functions, such as receiving, transmitting, and/or executing wind turbine control signals.

Referring now to FIG. 3, a simplified interior view of an embodiment of nacelle 16 of wind turbine 10 shown in FIG. 2 is shown. As shown, wind turbine 10 includes a generator 24 housed within nacelle 16 that is coupled to rotor 18 for generating electrical power from the rotational energy generated by rotor 18. For example, as shown, rotor 18 may include a rotor shaft 34 coupled to hub 20 for rotation therewith. The rotor shaft 34, in turn, may be rotatably coupled to a generator shaft 36 of the generator 24 by a gearbox 38, the gearbox 38 being connected to a bedplate support frame 48 by a torque support 50. As generally understood, rotor shaft 34 may provide a low speed, high torque input to gearbox 38 in response to rotation of rotor blades 22 and hub 20. The gearbox 38 may then be configured to convert the low-speed, high-torque input to a high-speed, low-torque output to drive the generator shaft 36, and thus the generator 24.

Each rotor blade 22 may also include a pitch adjustment mechanism 32, with the pitch adjustment mechanism 32 configured to rotate each rotor blade 22 about its pitch axis 28. Moreover, each pitch adjustment mechanism 32 may include a pitch drive motor 40 (e.g., any suitable electric, hydraulic, or pneumatic motor), a pitch drive gearbox 42, and a pitch drive pinion 44. In such embodiments, pitch drive motor 40 may be coupled to pitch drive gearbox 42 such that pitch drive motor 40 imparts mechanical force to pitch drive gearbox 42. Similarly, pitch drive gearbox 42 may be coupled to pitch drive pinion 44 for rotation therewith. Pitch drive pinion 44, in turn, may be in rotational engagement with a pitch bearing 46 coupled between hub 20 and corresponding rotor blade 22 such that rotation of pitch drive pinion 44 causes rotation of pitch bearing 46. Thus, in such embodiments, rotation of pitch drive motor 40 drives pitch drive gearbox 42 and pitch drive pinion 44, thereby rotating pitch bearing 46 and rotor blade 22 about pitch axis 28. Similarly, wind turbine 10 may include one or more yaw drive mechanisms 52 communicatively coupled to controller 26, wherein each yaw drive mechanism 52 is configured to change an angle of nacelle 16 with respect to the wind (e.g., by engaging a yaw bearing 54 of wind turbine 10).

Referring now to FIG. 4, a detailed perspective view of one embodiment of a platen 48 according to the present disclosure is shown. As shown, platen 48 includes: a base body 56 formed via at least one of casting or welding; and one or more additive 58 regions applied to an outer surface 60 of the base body 56 via an additive manufacturing process such that the structural capacity of the platen 48 is designed to withstand the load requirements of the platen 48.

Referring now to FIG. 5, a flow diagram of an embodiment of a method 100 for manufacturing a bedplate of wind turbine 10 is shown. In general, the method 100 will be described herein with reference to the wind turbine 10 and the bedplate 48 shown in fig. 2 and 3. However, it should be appreciated that the disclosed method 100 may be implemented with a wind turbine having any other suitable configuration. Additionally, although fig. 5 depicts steps performed in a particular order for purposes of illustration and discussion, the methods discussed herein are not limited to any particular order or arrangement. Using the disclosure provided herein, those skilled in the art will appreciate that various steps of the methods disclosed herein may be omitted, rearranged, combined, and/or adapted in various ways without departing from the scope of the present disclosure.

As shown at (102), the method 100 may include forming the base body 56 of the platen 48. Thus, the base body 56 of the platen 48 generally forms the near net shape of the platen 48. As used herein, near-net shape generally refers to a part that is very close to the final (net) shape, reducing the need for additive manufacturing processes. Thus, the near net shape reduces the required finishing, such as machining or grinding.

For example, in one embodiment, the method 100 may include forming the base body 56 of the platen 48 via casting or welding. In such embodiments, the casting process may include pouring the liquid material into a mold of the base body 56 of the platen 48 and allowing the liquid material to solidify in the mold so as to form the base body 56 of the platen 48. In another embodiment, the method may include forming the base body 56 of the platen 48 from steel, cast steel, iron, ductile iron, or any other suitable material having the desired strength and/or structural properties.

Still referring to FIG. 5, as shown at (104), the method 100 may include determining a load demand of the bedplate 48 of the wind turbine 10. More particularly, in one embodiment, load requirements may be determined via topology optimization. As used herein, topology optimization generally refers to a mathematical method that optimizes material placement within a given design space with the goal of maximizing system performance for a given set of loads, boundary conditions, and constraints. More particularly, as shown in fig. 6, a schematic diagram of one embodiment of a controller 62 configured to determine a load demand with respect to platen 48 is shown. As shown, the controller 62 may include a topology optimization module 64, the topology optimization module 64 configured to receive one or more boundary conditions 66 or constraints with respect to the platen 48 and/or one or more loads 68 (e.g., spindle load, torque, thrust, etc.).

It should be understood that the controller described herein may include one or more processors and associated memory devices configured to perform various computer-implemented functions (e.g., performing methods, steps, calculations, etc., and storing relevant data as disclosed herein). As used herein, the term "processor" refers not only to integrated circuits referred to in the art as being included in a computer, but also to controllers, microcontrollers, microcomputers, Programmable Logic Controllers (PLCs), application specific integrated circuits, and other programmable circuits. The processors described herein may also be configured to compute advanced control algorithms and communicate in various Ethernet or serial-based protocols (Modbus, OPC, CAN, etc.). Additionally, the memory device may generally include memory elements including, but not limited to, computer-readable media (e.g., Random Access Memory (RAM), computer-readable non-volatile media (e.g., flash memory), a floppy disk, a high-density compact disc-read only memory (CD-ROM), a magneto-optical disk (MOD), a Digital Versatile Disc (DVD), and/or other suitable memory elements). Such memory devices may generally be configured to store suitable computer-readable instructions that, when executed by a processor, cause the controller 62 to be configured to perform various functions as described herein.

More specifically, in one embodiment, topology optimization module 64 of controller 62 may receive a base design of platen 48. For example, the base design of platen 48 may be an initial, potentially over-designed shape. Thus, the topology optimization module 64 is configured to simplify the basic design by simplifying any complex features for mesh partitioning (mesh). Thus, the simplification of the basic design of platen 48 is configured to maximize design space while maintaining an interface. The topology optimization module 64 is then configured to add interfaces (e.g., which correspond to the main shaft 34, torque arm 50, yaw drive mechanism 52, etc.) and apply boundary conditions/constraints 66 to the simplified base design. Accordingly, the topology optimization module 64 may determine an optimized load path 70 for the platen 48 based on one or more boundary conditions 66 and/or loads 68 with respect to the platen 48. The optimized load path 70 may also optionally be post-processed, as shown at 72, for example to smooth the surface and/or to provide symmetry for the platen design.

Accordingly, referring back to fig. 5, as shown at (106), method 100 may include applying additive 58 to outer surface 60 of base body 56 of platen 48 via an additive manufacturing process in order to customize the structural capabilities of platen 48 such that the structural capabilities of platen 48 may withstand the load requirements of platen 48. In other words, method 100 includes using optimized load path 70 as a roadmap for applying additive 58 to base body 56.

As used herein, additive manufacturing generally refers to a process for producing a three-dimensional object in which layers of material are deposited or formed under computer control to produce the object. Thus, in certain embodiments, the additive manufacturing processes described herein may include, for example, directed energy deposition, binder jetting, material jetting, or any other suitable additive manufacturing technique. Thus, in one embodiment, additive 58 may be deposited via a Computer Numerical Control (CNC) device onto base body 56 of platen 48 layer-by-layer to build up additive 58 to form one or more structural components 74, which structural components 74 increase the structural capacity of platen 48. Thus, in one embodiment, the additive 58 may be applied to the outer surface 60 of the base body 56 by printing one or more structural components 74 at one or more locations on the outer surface 60 of the base body 56 to correspond to an optimized load path. Thus, method 100 may include applying additive 58 to outer surface 60 of base body 56 of platen 48 as desired. In further embodiments, the additive 58 used in the additive manufacturing process may include, for example, a steel alloy, an iron alloy, or a combination thereof, or the like.

Referring now to FIG. 7, a flow diagram of one embodiment of a method 200 for customizing a bedplate for a plurality of wind turbines having different load requirements is shown. In general, the method 100 will be described herein with reference to the wind turbine 10 illustrated in FIGS. 2 and 3. However, it should be appreciated that the disclosed method 100 may be implemented with a wind turbine having any other suitable configuration. Additionally, although fig. 7 depicts steps performed in a particular order for purposes of illustration and discussion, the methods discussed herein are not limited to any particular order or arrangement. Using the disclosure provided herein, those skilled in the art will appreciate that various steps of the methods disclosed herein may be omitted, rearranged, combined, and/or adapted in various ways without departing from the scope of the present disclosure.

As shown at (202), the method 200 may include forming a plurality of base bodies 56 for the platens 48, each forming a near-net shape of one of the platens 48. As shown at (204), method 200 may include determining a load demand of bedplate 48 of each of wind turbines 10. For example, as mentioned, the topology optimization module 64 is configured to generate optimized load paths for the plurality of platens 48. As shown at (206), method 200 may include applying additive 58 to outer surfaces 60 of a plurality of base bodies 56 via an additive manufacturing process in order to customize the structural capabilities of each of platens 48 such that the structural capabilities of each of platens 48 may withstand load requirements with respect to each of wind turbines 10. Accordingly, the structural capabilities of each of the plurality of base bodies 48 may be the same or may be different.

Accordingly, the method 200 is configured to affect (leverage) additive manufacturing to customize and enhance the design of the base cast platen so as to improve the structural capabilities of the platen so that it may be used in areas with higher than average loads without designing entirely new platens or wind turbines. Thus, additive techniques may enable having multiple deck designs that may be customized for a given wind turbine site.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.